Process for forming high activity catalysts

ABSTRACT

Provided are high activity catalysts based upon gamma alumina containing substrates impregnated with one or more catalytically active metals, which catalysts in addition contain a nanocrystalline phase of alumina of a crystalline size at the surface of less than 25 Å. Also provided are processes for preparing such high activity catalysts and various uses thereof.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation of application Ser. No. 09/434,417 filed Nov. 4,1999, which is a division of application Ser. No. 08/433,381 filed asPCT/US94/05293, May 13, 1994, now U.S. Pat. No. 6,016,485.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to high activity catalysts basedupon gamma alumina containing substrates impregnated with one or morecatalytically active metals, processes for preparing the same and usesthereof. More specifically, the present invention relates to process forimproving the activity of such catalysts, the improved activitycatalysts produced thereby, and various specific catalysts and usesthereof.

2. Description of Related Art

The art relating to particulate porous gamma alumina containingsupports, impregnating such supports with various catalytically activemetals, metal compounds and/or promoters, and various uses of suchimpregnated supports as catalysts, is extensive and relatively welldeveloped. As a few of the many exemplary disclosures relating to thesefields may be mentioned the following United States patents, all ofwhich are incorporated herein by reference for all purposes as if fullyset forth—U.S. Pat. Nos. 2,935,463, 3,032,514, 3,124,418, 3,152,865,3,232,887, 3,287,280, 3,297,588, 3,493,493, 3,749,664, 3,778,365,3,897,365, 3,909,453, 3,983,197, 4,090,874, 4,090,982, 4,154,812,4,179,408, 4,255,282, 4,328,130, 4,357,263, 4,402,865, 4,444,905,4,447,556, 4,460,707, 4,530,911, 4,588,706, 4,591,429, 4,595,672,4,652,545, 4,673,664, 4,677,085, 4,732,886, 4,797,196, 4,861,746,5,002,919, 5,186,818, 5,232,888, 5,246,569 and 5,248,412.

While the prior art shows a continuous modification and refinement ofsuch catalysts to improve their catalytic activity, and while in somecases highly desirable activities have actually been achieved, there isa continuing need in the industry for even higher activity catalysts,which are provided by the present invention.

As an example of this need may be mentioned the need for a higheractivity first stage hydrocracking catalyst. In a typical hydrocrackingprocess, higher molecular weight hydrocarbons are converted to lowermolecular weight fractions in the presence of a hydrocracking catalystwhich is normally a noble metal impregnated silica-alumina/zeolite.State-of-the-art hydrocracking catalysts possess a very high activityand are capable of cracking high volume throughputs. Such catalysts,however, are highly sensitive to contaminants such as sulfur, metals andnitrogen compounds, which consequently must be removed from thehydrocarbon stream prior to the cracking. This is accomplished in firststage hydrocracking processes such as hydrodenitrogenation,hydrodesunfirization and hydrodemetallation. Hydrotreating catalystsutilized in these processes are typically a combination Group VIB andGroup VIII metal impregnated alumina substrate. State-of-the-arthydrotreating catalysts, however, are not sufficiently active to allowprocessing of the same high volume throughputs as can be processed bythe hydrocracking catalysts. As such, the first stage hydrocrackingprocesses form a bottleneck in the overall hydrocracking process, whichmust be compensated, for example, in the size of the hydrotreating unitrelative to the hydrocracking unit.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a highactivity catalyst composition comprising, in one aspect, a particulateporous support containing gamma alumina, having a surface area of atleast 100 square meters (as measured by nitrogen adsorption) and a porevolume of at least 0.25 cubic centimeters per gram (as measured bymercury porosimetry), and impregnated with one or more catalyticallyactive metals, whereby the catalyst further contains in part ananocrystalline phase of alumina of a crystallite size at the surface ofup to 25 Å.

In another aspect, the present invention provides a high activitycatalyst comprising a particulate porous support containing gammaalumina, having a surface area of at least 100 square meters (asmeasured by nitrogen adsorption) and a pore volume of at least 0.25cubic centimeters per gram (as measured by mercury porosimetry), andimpregnated with one or more catalytically active metals, and whichcatalyst displays a relative volume activity (RVA) of at least 115,preferably at least 120, and especially at least 125, in a first stagehydrocracking process as measured by the procedure described in thearticle by Carruthers and DiCamillo, “Pilot Plant Testing ofHydrotreating Catalysts,” Applied Catalysts, 43 (1988) 253-276,utilizing as the standard a catalyst commercially available under thetrade designation HC-H (as of May 1994) from Unocal Corporation, Brea,Calif.

In addition to the above catalyst, the present invention also provides aprocess for improving the activity of a catalyst composition comprisinga particulate porous support comprising gamma alumina and amorphousalumina, having a surface area of at least 100 square meters (asmeasured by nitrogen adsorption) and a pore volume of at least 0.25cubic centimeters per gram (as measured by mercury porosimetry), andimpregnated with one Or more catalytically active metals, by the stepsof:

(1) wetting the catalyst composition by contact with a chelating agentin a carrier liquid;

(2) aging the so-wetted substrate while wet;

(3) drying the so-aged substrate at a temperature and under conditionsto substantially volatilize the carrier liquid; and

(4) calcining the so-dried substrate.

This process can readily be applied to existing catalysts comprising aparticulate porous support containing gamma alumina and amorphousalumina, or can be utilized in a catalyst manufacture process prior to,concurrently with and/or subsequent to the impregnation of the supportcontaining gamma alumina and amorphous alumina, with one or morecatalytically active metals and/or compounds thereof. In addition, theprocess can be utilized to improve the activity of spent catalystsduring regeneration, which spent catalysts comprise a particulate poroussupport containing gamma alumina and amorphous alumina, wherein thespent catalyst is wetted as in step (1) above subsequent to the removalof carbonaceous deposits therefrom, followed by steps (2), (3) and (4).

By performing these steps in the indicated order, it is believed(without wishing to be bound by any particular theory) that aninteraction takes place between at least the amorphous gamma alumina,chelating agent and catalytically active components, resulting in theappearance of a nanocrystalline phase of alumina of a crystallite sizeat the surface of the catalyst of up to 25 Å, and preferably between 8 Åand 25 Å, in combination with the gamma alumina which has a crystallitesize at the surface of the catalyst of greater than 30 Å, and typicallyin the range of 30 Å to 70 Å. Crystallite size at the catalyst surfacecan be measured via well-known techniques involving transmissionelectron microscopy.

Concurrent with the appearance of this nanocrystalline phase, anincrease in the surface area of the catalyst is also achieved. Inaddition, in preferred embodiments, an at least bimodal mesoporestructure is generated with a porosity peaking in a first region of poresize 40 Å or less, and more preferably in the range of 20 Å to 40 Å, andin a second region of pore size 50 Å or greater, and more preferably inthe range of 50 Å to 150 Å, as measured by nitrogen porosimetry usingthe desorption isotherm.

The resulting high activity catalysts find use in a wide variety offields as detailed in the many previously incorporated references. Aparticularly preferred use is as a first stage hydrocracking catalyst inhydrodenitrogenation, hydrodesulirization and hydrodemetallation.

These and other features and advantages of the present invention will bemore readily understood by those of ordinary skill in the art from areading of the following detailed description.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Substrates

As indicated above, substrates suitable for use preparing the catalystsof the present invention are particulate porous substrates whichcomprise at least in part gamma alumina and amorphous alumina, andpreferably at least 5 wt % amorphous alumina based on the weight of thesubstrate. As specific examples may be mentioned substantially aluminasubstrates, as well as composite substrates in which the alumina acts atleast in part as a carrier for other substrates such as silica-aluminasand zeolites. Such substrates and their methods of manufacture are ingeneral well-known to those of ordinary skill in the art, as exemplifiedby the many previously incorporated references, and reference may be hadthereto for further details.

Catalytically Active Metals

The present invention is applicable to catalysts impregnated with one ormore of a wide variety of catalytically active metals well-known tothose of ordinary skill in the art as exemplified, for example, by thenumerous incorporated references. In the context of the presentinvention, “catalytically active metals” includes both the metalsthemselves as well as metal compounds. In addition to the catalyticallyactive metals, the catalysts may also be impregnated with one or morewell-known promoters such as phosphorous, tin, silica and titanium(including compounds thereof).

Typically, the catalytically active metals are transition metalsselected from the group consisting of Group VIB metals, Group VIIImetals and combinations thereof. The specific choice of metal(s),promoter(s) and loadings, of course, depends upon the desired end use ofthe catalyst, and these variables can readily be adjusted by those ofordinary skill in the art based upon the end use. As specific examplesthereof may be mentioned the following (wt % is based on the totalcatalyst weight):

Hydrotreating Operations Hydro- Ni and/or Co, and preferably Ni, in anamount up to denitrogenation 7 wt % calculated as NiO and/or CoO Moand/or W, preferably Mo, in an amount up to 35 wt % calculated as MoO₃and/or WO₃ optionally P, and preferably including P, in an amount up to10 wt % calculated as P₂O₅ Hydro- Ni and/or Co, and preferably Co, in anamount up to desulfurization 9 wt % calculated as NiO and/or CoO Moand/or W, preferably Mo, in an amount up to 35 wt % calculated as MoO₃and/or WO₃ optionally P, and preferably including P, in an amount up to10 wt % calculated as P₂O₅ Hydrodemetallation optionally Ni and/or Co,and preferably including Ni and/or Co, in an amount up to 5 wt %calculated as NiO and/or CoO Mo and/or W, preferably Mo, in an amount upto 20 wt % calculated as MoO₃ and/or WO₃ optionally P, and preferablyincluding P, in an amount up to 10 wt % calculated as P₂O₅Hydroconversion Ni and/or Co, and preferably Ni, in an amount up to 5 wt% calculated as NiO and/or CoO Mo and/or W, preferably Mo, in an amountup to 20 wt % calculated as MoO₃ and/or WO₃ optionally P, and preferablyincluding P, in an amount up to 6 wt % calculated as P₂O₅ HydrocrackingNi and/or Co, and preferably Ni, in an amount up to 5 wt % calculated asNiO and/or CoO Mo and/or W, preferably Mo, in an amount up to 20 wt %calculated as MoO₃ and/or WO₃ optionally P, and preferably including P,in an amount up to 10 wt % calculated as P₂O₅ Hydrogenation/ a noblemetal, and preferably Pt or Pt in combina- Dehydrogenation tion with Rh,in an amount up to 2 wt % calculated on an elemental basis Reforming anoble metal, and preferably Pt or Pt in combina- tion with another noblemetal such Re and/or Ir, and/or Sn, in an amount up to 2 wt % calculatedon an elemental basis Non-Hydrotreating Operations Isomerization a noblemetal, and preferably Pt or Pt in combina- tion with another noblemetal, in an amount up to 2 wt % calculated on an elemental basis ClausProcess Ni and/or Co, and preferably Ni, in an amount up to 5 wt %calculated as NiO and/or CoO Mo and/or W, preferably Mo, in an amount upto 20 wt % calculated as MoO₃ and/or WO₃ optionally P, and preferablyincluding P, in an amount up to 6 wt % calculated as P₂O_(5.)

Such catalysts are prepared by impregnating the substrates with theappropriate components, followed by various drying, sulfiding and/orcalcining steps as required for the appropriate end use. Such catalystpreparation is generally well-known to those of ordinary skill in therelevant art, as exemplified by the numerous previously incorporatedreferences, and further details may be had by reference thereto ornumerous other general reference works available on the subject.

The Inventive Process

As indicated above, the activity of catalytically active metalimpregnated carriers comprising gamma alumina and amorphous alumina isimproved in accordance with the present invention by the steps of:

(1) wetting the catalyst composition by contact with a chelating agentin a carrier liquid;

(2) aging the so-wetted substrate while wet;

(3) drying the so-aged substrate at a temperature and under conditionsto substantially volatilize the carrier liquid; and

(4) calcining the so-dried substrate.

Chelating agents suitable for use in this process include those known toform more stable complexes with transition metals and aluminum and,consequently, possess high stability constants with respect thereto.Particularly preferred for use in the present invention isethylenediaminetetraacetic acid (EDTA) and derivatives thereofincluding, for example, N-hydroxy ethylenediaminetetraacetic acid anddiammonium ethylenediaminetetraacetic acid. Also suitable aretris(2-aminoethyl)amine and triethylenetetraamine. Other candidatesinclude diethylenetriaminepentaacetic acid,cyclohexanediaminetetraacetic acid,ethyleneglycol-bis-(beta-aminoethylether)-N, N′-tetraacetic acid,tetraethylenepentaamine and the like. The suitability of other chelatingagents can be readily determined by those of ordinary skill in the artby treating a catalyst sample in accordance with the present inventionthen determining with the aid of transmission electron microscopywhether or not the nanocrystalline alumina structure of appropriatecrystallite size has formed.

The amount of chelating agent utilized is not critical to obtaining theeffect, but does have an influence on the degree of effect. Widelyvarying amounts of chelating agent can utilized depending on a number offactors such as solubility in the carrier liquid, type of catalystsupport and metals impregnated or to be impregnated thereon. Generally,the catalyst composition should be wetted by a carrier liquid containingthe chelating agent in amounts ranging from 0.01-1.0 grams of chelatingagent per gram of catalyst composition.

The catalyst composition may be wetted by any normal method such asdipping or spraying. To ensure adequate infiltration of the chelatingagent, dipping is preferred followed by a soaking period. The preferredcarrier liquid is water or a water/ammonia solution.

Aging of the substrate is a function of the temperature during aging. Atroom temperature, it is preferred to age the wetted substrate for atleast 10 days, more preferably at least 14 days. As temperatureincreases, the required aging time decreases. At 60° C., it is preferredto age the wetted substrate for at least one day, more preferably atleast three days. The aging can be further accelerated to as little asone hour by heating the wetted sample in a microwave oven. Preferablyaging is accomplished at a temperature in the range of 20° C. to 90° C.

Subsequently, the aged catalyst is dried to substantially remove thecarrier liquid. It is preferred that the drying take place rapidly atelevated temperatures in the range of 100° C. to 250° C. Preferably, aforced air heater is utilized to speed drying to a preferred time ofless than one hour.

The so-dried catalyst is then calcined under conditions well-known tothose of ordinary skill in the art. Preferably, however, the calcinationtakes place in two stages—a first lower temperature stage in which thetemperature is sufficiently high to drive off or decompose any remainingchelating agent, but which is not so high that the chelating agentscombusts to form carbonaceous deposits. This first stage temperaturewill vary depending on the particularly chelating agent, but typically atemperature within the range of 250° C. to 350° C. will be sufficient.Once any remaining chelating agent is substantially removed, thecatalyst may then be calcined under the normal higher temperatureconditions commonly utilized.

As indicated above, the process in accordance with the present inventionis not only applicable to pre-formed catalysts, but also can be appliedto regenerated catalysts in a like manner. Specifically, subsequent tothe removal of carbonaceous material from a spent catalyst viawell-known procedures, such catalysts are then be treated by steps (1)through (4) in an identical manner as described above.

This procedure can also be adapted during the production of newcatalyst. Specifically, the substrate can be wetted with the chelatingagent/carrier liquid either prior to, concurrently with and/orsubsequent to the impregnation of the support with the appropriatecatalytically active metals, followed by steps (2) through (4) asdescribed above. It is only important to ensure that the aging steptakes place while the impregnated support is wet from the carrier liquidfor the chelating agent and/or impregnation metals.

The present invention as described above will be further exemplified bythe following specific examples which are provided by way ofillustration and not limitation thereof.

The abbreviations in these examples have the following meanings:

EDTA ethylenediaminetetraacetic acid

MEA monoethanolamine

SA(N₂) surface area measured by nitrogen adsorption

SA/gAl₂O₃ surface area per gram alumina

RVA relative volume activity in a 1st stage hydrocracking test, measuredas described in the article by Carruthers and DiCamillo, “Pilot PlantTesting of Hydrotreating Catalysts”, Applied Catalysts, 43 (1988)253-276. The relative volume activity is determined utilizing as thestandard a catalyst commercially available (as of May 1994) under thetrade designation HC-H from Unocal Corporation, Brea, Calif.

RWA relative weight activity, determined in accordance with theaforementioned article.

EXAMPLE 1

266 grams of an alumina catalyst support, commercially available fromCriterion Catalyst Company (Houston, Tex.), prepared from alumina powdercontaining some amorphous alumina hydrate, and with a pore volume of0.62 cc/g (as measured by mercury porosimetry) and pore size peaking at78 Å (as measured by nitrogen porosimetry using the desorptionisotherm), were placed in a stainless basket and dipped into 1800 mls.of an aqueous impregnating solution. The impregnating solution,identified as solution ‘A’, was prepared by dissolving 900 grams ofmolybdenum trioxide and 221 grams of nickel oxide in a dilute solutionof phosphoric acid (263 grams of 85% solution in 1509 g of DI water). Tothe solution was added 226 grams of solid EDTA. The solution was thenrecirculated over the alumina support for one hour. The wet impregnatedsupport was then removed from the basket and centrifuged.

The wet support was split into four lots and allowed to age in a sealedcontainer at room temperature for 2 hours, 3 days, 14 days and 22 days.Following this, each lot was dried using either a standard dryingprocedure (250° F. (121° C.) for 1 hour) or a fast drying procedure(300° F. (149° C.) for 20 mins. with high air flow). Each sample wasthen transferred to a muffle furnace and calcined at 850° F. (454° C.)for 1 hour. The resulting catalysts are identified as E1, E2, E3, E4 andE5 in Table 1 below.

A second series of catalysts was prepared in an identical manner asabove except that in place of the EDTA was added 94.3 grams of MEA. Thewet impregnated support was split into two portions and aged at roomtemperature for 2 hours and 15 days. The catalysts were dried using theFast Dry procedure and calcined as described above. The resultingcatalysts are identified as M1 and M2 respectively in Table 1.

A third series of catalysts prepared in an identical manner as set forthabove, except that in place of the EDTA was added 183 grams of succinicacid. The wet impregnated support was then split into two portions andaged at room temperature for 2 hours and 18 days. The catalysts weredried using the Fast Dry procedure and calcined as described above. Theresulting catalysts are identified as SI and S2 respectively in Table 1.

A fourth series of catalysts was prepared in an identical manner as setforth above, except that in place of the EDTA was added 216 grams ofcitric acid. The wet impregnated support was then split into threeportions and aged at room temperature for 2 hours, 2 days and 9 days.The catalysts were dried using the Fast Dry procedure and calcined asdescribed above. The resulting catalysts are identified as C1, C2 and C3in Table 1.

Finally, a control series of catalysts was prepared in an identicalmanner as set forth above, except that no EDTA was added. The wetimpregnated support was split into two portions and aged at roomtemperature for 2 hours and 12 days. The catalysts were dried using theFast Dry procedure and calcined as described above. The resultingcatalysts are identified in Table 1 below as A1 and A2.

Although some surface area increase was measured for each of the samplesaged beyond 10 days, only one chelating agent of this set, EDTA, broughtabout a significant increase in catalytic activity (samples E4 and E5).Similarly, in parallel with the catalyst activity results, AnalyticalElectron Microscopy (AEM) showed clear evidence for the presence of the“nanocrystalline” phase of alumina in the EDTA treated and aged samplesbut not in the alumina of the other samples treated with other agents,nor in the alumina of the untreated samples A1 and A2.

TABLE 1 Sample Age Drying SA(N₂) RVA-TN ID Agent Time Method m²/g % E1EDTA 2 hrs Fast dry 163 94 E2 EDTA 3 days Fast dry 198 87 E3 EDTA 14days Slow dry 192 107 E4 EDTA 14 days Fast dry 195 120 E5 EDTA 22 daysFast dry 203 125 M1 MEA 2 hrs Fast dry 179 100 M2 MEA 15 days Fast dry187 109 S1 Suc. acid 2 hrs Fast dry 180 103 S2 Suc. acid 18 days Fastdry 201 110 C1 Citric acid 2 hrs Fast dry 181 92 C2 Citric acid 2 daysFast dry 186 110 C3 Citric acid 9 days Fast dry 206 100 A1 None 2 hrsFast dry 160 98 A2 None 12 days Fast dry 170 101

EXAMPLE 2

188 grams of the alumina support described in Example 1 was processedwith 1300 ml. of solution ‘A’ in an identical manner to in Example 1,except that in place of the EDTA was added 100 grams of soliddiammonium-EDTA.

The wet impregnated support was split into two lots, and one portionallowed to age at room temperature (68° F. 20° C.) for 2 hours while asecond portion was placed in a sealed container and aged at 140° F. (60°C.) for 17 hours. The two portions were dried at 450° F. (232° C.) for20 mins. prior to finishing in a calciner at 800° F. (427° C.). Thesamples are identified in Table 2 as DE1 and DE2 respectively. Thesample aged for 17 hrs. at 140° F. (60° C.) and fast-dried exhibitedhigh catalytic activity, similar to that obtained using the EDTA acid inExample 1 above.

TABLE 2 Sample Age Time Age Temp SA(N₂) SA/gAl₂O₃ RVA-TN ID hours ° F.(° C.) m²/g m²/g % DE1 2  68 (20) 164 253 100 DE2 17 140 (60) 170 262120

EXAMPLE 3

100 grams of the alumina support described in Example 1 was impregnatedby saturating the pore structure of the support with solution ‘B’,prepared by adding 46.7 grams of a solution ‘C’ comprising 36.8 wt. %molybdenum trioxide, 6.5 wt. % nickel oxide and 10.0 wt. % phosphoruspentoxide to 30 grams of a 44.7 wt. % solution of diammonium EDTA and 23mis. of concentrated (29 wt.%) ammonia. The material was then aged for 2hours and dried in a two step process, first at 250° F. (121° C.) for 2hours and then at 500° F. (260° C.) for a further 2 hours.

The dried catalyst was then subjected to a second pore saturation usingsolution ‘D’, which comprised 46.7 grams of solution ‘C’ diluted with 23mls. of water. The wet impregnated support was then aged in a sealedvessel at 158° F. (70° C.) for 18 hours in an oven. The catalyst wasFast Dried and calcined in the same manner as described before. Thecatalyst is designated ‘F’ in Table 3.

TABLE 3 Sample NiO MoO₃ P₂O₅ SA(N₂) SA/gAl₂O₃ RVA-TN ID wt % wt % wt %m²/g m²/g % F1 3.86 24.2 5.75 200 303 121

EXAMPLE 4

750 grams of an alumina catalyst support commercially available fromCriterion Catalyst Company (Houston, Tex.) prepared from alumina powdercontaining some amorphous alumina hydrate with a pore volume of 0.78cc/g and a pore size of 82 angstroms was placed in a stainless basketand dipped into 5300 ml. of a solution ‘E’ comprising 32 wt. %molybdenum trioxide, 7.2 wt. % nickel oxide and 10.7 wt. % phosphoricacid. The solution was then recirculated over the alumina support forone hour after which the wet support was removed from the basket andcentrifuged.

The wet impregnated support was allowed to age for 2 hours at roomtemperature and then dried at 250° F. (121° C.) in an oven and calcinedat 800° F. (427° C.) for 1 hour.

Seven 100 gram samples of the finished catalyst were then subjected topore volume saturation using eight different aqueous solutions ofchelating agents:

(1) 7.6 g. of Ethylenediamine-N,N-diacetic acid in 47 ml. of solution.

(2) 8.25 g. of Nitrilotriacetic acid in 37 ml. of solution.

(3) 12.7 g. of tris-(2-aminoethyl)amine in 37 ml. of solution.

(4) 8.0 g. of Ethylenediamine in 38 ml. of solution.

(5) 8.0 g. of Ethylene Glycol in 37 ml. of solution.

(6) 11.5 g. of Triethylene tetramine in 37 ml. of solution.

(7) 31.5 g. of a 44.7 wt. % diammonium ethylenediamine tetraacetic acidsolution in 40 ml. of solution.

Each sample was then aged at 167° F. (75° C.) in a sealed container for3 days, allowed to cool and then Fast Dried at 450° F (232° C.) for 20mins. prior to final calcination at 850° F. (454° C.). Each catalyst wasthen analyzed and activity tested in the 1st. Stage Hydrocrackingcatalyst test for nitrogen removal (Table 4).

TABLE 4 S.A(N₂) SA/gAl₂O₃ RVA m²/g m²/g % (1)Ethylenediamine-N,N-diacetic acid 143 242 108 (2) Nitrilotriacetic acid173 293 102 (3) Tris(2-aminoethyl) amine 166 281 133 (4) EthyleneDiamine 167 283 106 (5) Ethylene Glycol 137 232 106 (6) Triethylenetetramine 160 271 126 (7) Diammonium EDTA 205 347 137 (8) Nochelatingagent 132 224 101

EXAMPLE 5

150 grams of an alumina catalyst support commercially available fromCriterion Catalyst Company (Houston, Tex.) prepared from alumina powdercontaining some amorphous alumina hydrate with a pore volume of 0.71cc/g and a pore size of 78 angstroms was pore saturated with a solution‘F’ containing 240 grams of diammonium-EDTA in 1 liter of aqueoussolution. A second 150 gram sample of support was then pore saturatedwith a 66:33 solution ‘F’: water mixture. A third 150 gram sample wasthen prepared by pore saturation with a 50:50, solution ‘F’: watermixture.

Each of the wet impregnated supports was then allowed to stand for 2hours followed by drying in an air oven at 450° F. (232° C.). Each driedmaterial was then placed in a stainless basket and dipped into 1200 ml.of solution ‘E’ (see Example 4). The solution was then recirculated overthe dried alumina support containing the diammonium-EDTA for one hourafter which the pills were centrifuged and allowed to age in a sealedcontainer for 64 hours at 140° F. (60° C.). The wet catalyst was thenfast dried at 450° F. (232° C.) for 20 minutes in air, and calcined at800° F. (427° C.) for one hour.

The finished catalysts differed in surface area on both a “per gram ofcatalyst” basis as well as on a “per gram of alumina” basis. Thecatalyst activities in the hydrodenitrogenation test declined stepwise,paralleling the decreasing catalyst surface areas and the correspondingdecreasing concentrations of pre-impregnated diammonium-EDTA (Table 5).

TABLE 5 S.A(N₂) SA/gAl₂O₃ RVA RWA m²/g m²/g % % 100% Sol ‘F’ 240 350 124137  66% Sol ‘F’ 207 314 116 124  50% Sol ‘F’ 198 301 118 124

EXAMPLE 6

150 grams of the alumina support described in Example 4 was poresaturated with a solution ‘G’ containing 48 grams of diammonium-EDTA, 9grams of 29 wt. % ammonium hydroxide and 12.7 grams of nickel nitratehexahydrate in 114 ml. of aqueous solution. The wet material was allowedto stand for 2 hours before being dried at 250° F. (121° C.) for 1 hourin an air oven followed by drying at 375° F. (191° C.) for 1 hour. Thedried material was then placed in a stainless basket and dipped into asolution ‘H’ containing 35.6 wt. % molybdenum trioxide, 9.1 wt. %phosphoric acid and 7.3 wt. % nickel oxide. The solution was thenrecirculated over the dried alumina support containing thediammonium-EDTA for one hour after which the pills were centrifuged. Theresulting material was split into two parts, with one part allowed toage at room temperature for three weeks (sample 6A) while the other partwas placed in a sealed container and allowed to age for 72 hours at 167°F. (75° C.) (sample 6B). Both parts were subsequently fast dried at 450°F. (232° C.) for 20 mins. and calcined in two stages: at 575° F. (302°C.) for 30 minutes followed by 850° F. (454° C.) for one hour. Thefinished catalysts exhibited very similar surface areas and highactivities in 25 the hydrodenitrogenation test (Table 6).

EXAMPLE 7

200 grams of the alumina support described in Example 4 was poresaturated with a solution ‘J’ containing 48 grams of diammonium-EDTA,15.3 grams of 29 wt. % ammonium hydroxide and 62 grams of solution ‘K’comprising 32.8 wt. % molybdenum trioxide, 5.9 wt. % nickel oxide and9.0 wt. % phosphoric acid. The wet impregnated support was then allowedto stand for 2 hours and dried, first at 250° F. (121 ° C.) for 1 hourand then at 450° F. (232° C.) for 1 hour. The dried material was thenplaced in a stainless basket and dipped into 1400 ml of solution ‘H’.The solution was then recirculated over the dried alumina supportcontaining the diammonium-EDTA for one hour after which the pills werecentrifuged. The resulting material was allowed to age in a sealedcontainer for 3 days at 167° F. (75° C.) (sample 7A), and wassubsequently fast dried at 450° F. (232° C. for 20 minutes and calcinedin two stages as set forth in Example 6. The surface area enhancementand catalyst activity in the hydrodenitrogenation test were both veryhigh. The results are also shown in Table 6.

TABLE 6 Sample Age Time Age Temp SA(N₂) SA/gAl₂O₃ RVA-TN ID hours ° F.(° C.) m²/g m²/g % 6A 72 167 (75) 244 402 132 6B 504  68 (20) 208 343134 7A 161 167 (75) 259 401 136

EXAMPLE 8

300 grams of the alumina support described in Example 4 was poresaturated with a solution containing 80 grams of diammonium EDTA, 25.2grams of 29 wt. % ammonium and 92 grams of solution ‘K’ (see Example 7).The wet impregnated support was then allowed to stand for 2 hours anddried first at 250° F. (121° C.) for 1 hour then at 450° F. (232° C.)for another hour. The dried material was then placed in a stainlesssteel basket and dipped into 1900 ml. of solution ‘H’. The solution wasthen recirculated over the dried alumina support containing thediammonium-EDTA for one hour after which the pills were centrifuged. Theresulting material was split into two portions, with one part allowed toage for 16 hrs. at 167° F. (75° C.) (sample 9A) while the second partwas aged for 1 hour in a sealed container in a Microwave oven set tocontrol the temperature of the catalyst at 167° F. (75° C.) (sample 9B).The samples were subsequently Fast Dried and calcined as before.

The surface area enhancement and catalytic activities for the twomaterials were both good (Table 7).

TABLE 7 Sample Age Time Age Temp SA(N₂) SA/gAl₂O₃ RVA-RN ID hours ° F.(° C.) m²/g m²/g % 9A 1 167 (75) 173 284 125 9B 16 167 (75) 189 306 127

EXAMPLE 9

310 grams of a commercially regenerated used sample of Criterion C424catalyst (Criterion Catalyst Company, Houston, Tex.) was pore saturatedwith a solution containing 54.7 grams of diammonium EDTA. The sample wasthen aged at 140° F. (60° C.) in a sealed container for 4 days followedby Fast Drying and calcination as before (sample 10A). Both thecommercially regenerated sample of C424 (sample 10B) and theEDTA-treated sample were activity tested in a test designed to comparethe performance of catalysts in Catalytic Hydrotreatment of feedstockprior to Fluid Cat. Cracking (a CFH test). Results of the test and thetest conditions are shown in Table 8. It can be seen that theEDTA-treated regenerated catalyst had a significantly improvedperformance compared to the regenerated catalyst in both HDS and HDN.

TABLE 8 RVA-HDN RVA-HDS Sample ID Description % % C-424 Fresh 100 10010B Regenerated 75 69 10A Regenerated/ 90 86 EDTA treated

CFH Test: Feed: Cat. Cracked Heavy Gas Oil H₂ Pressure: 1100 psig (76atm) H₂/Oil: 4210 SCF/bbl (0.75 m³/l) LHSV: 2 hr⁻¹ Temperature: 630° F.(332° C.)

We claim:
 1. A process for preparing a catalyst composition having aparticulate porous support comprising gamma alumina having a crystallitesize of greater than 30 Å, wherein the catalyst composition comprises atleast one catalytically active metal and a nanocrystalline phase ofalumina of a crystallite size up to 25 Å at the surface, and has amesopore structure exhibiting porosity peaking in a first region of 40 Åor less, as measured by nitrogen porosimetry using the desorptionisotherm, the process comprising the steps of: (1) impregnating aparticulate porous support comprising gamma alumina and amorphousalumina, with one or more catalytically active metals; (2) prior to,concurrently with, or subsequent to step (1), wetting the support bycontact with ahelating agent in a carrier liquid; (3) aging the wettedsupport while wet; (4) drying the aged support at a temperature andunder conditions to substantially volatilize the carrier liquid; and (5)calcining the dried support.
 2. The process of claim 1, wherein thenanocrystalline phase of alumina has a crystallite size of from 8 Å to25 Å.
 3. The process of claim 1, wherein the support has a surface areaof at least 100 square meters per gram, as measured by nitrogenporosimetry, and a pore volume of at least 0.25 cubic centimeters pergram as measured by mercury porosimetry.
 4. The process of claim 1,wherein the mesopore structure is an at least bimodal mesopore structurehaving a second region of pore size of 50 Å or greater, as measured bynitrogen porosimetry using the desorption isotherm.
 5. The process ofclaim 4, wherein in the catalyst possesses a bimodal mesopore structurewith a porosity peaking in a first region of pore size of 20 Å to 40 Åand a second region of pore size of 50 Å to 150 Å, as measured bynitrogen porosimetry using the desorption isotherm.
 6. The process ofclaim 1, wherein the chelating agent possesses a high stability constantwith respect to the catalytically active metals of the catalyst.
 7. Theprocess of claim 1, wherein the chelating agent isethylenediaminetetraacetic acid or a derivative thereof.
 8. The processof claim 1, wherein the chelating agent is selected from the groupconsisting of ethylenediaminetetraacetic acid, diammoniumethylenediaminetetraacetic acid, tris(2-aminoethyl)amine andtriethylenetetraamine.
 9. The process of claim 1, wherein the agedsubstrate is dried at a temperature in the range of 100° C. to 250° C.10. The process of claim 1, wherein the aged substrate is dried with theaid of a forced air heater.
 11. The process of claim 1, wherein thedried substrate is calcined in a first stage at a temperature which issufficiently high to drive off or decompose the chelating agent butwhich is not so high that the chelating agent combusts to formcarbonaceous deposits, and in a second stage at normal calciningtemperatures.